CarBEN EV5 Full Sized Prototype Construction - 5 Seat Electric Car From Scratch

[freebeard]

It's not like you owe me anything, I'm just curious. Is it compatible with polyester or epoxy resins?

The pieces aren't big enough to really do anything, but you could lay a rod along the edge of a slab, wrap it wih the textile soaked in resin; and then when it cures hit it with a hammer. You can't not learn anything.

“If we knew what we were doing, it wouldn't be called research” ― Albert Einstein

[palmer_md]

Can a moderator move the Basalt composite talk to a separate thread and leave a link here in this one for those who are interested in following....I like it, just seems it deserves its own thread, and this one will be cleaner if we keep talk contained to Carben.

[deejaaa]

Originally Posted by freebeard

It's not like you owe me anything, I'm just curious. Is it compatible with polyester or epoxy resins?

The pieces aren't big enough to really do anything, but you could lay a rod along the edge of a slab, wrap it wih the textile soaked in resin; and then when it cures hit it with a hammer. You can't not learn anything.

“If we knew what we were doing, it wouldn't be called research” ― Albert Einstein

sounds like a good test. will try it.

[NeilBlanchard]

I glued the the nose onto the chassis today.



I also worked on fitting the hood. I also removed the two chines, and I am going to omit the vent bezel - I can't figure out how to fit it an also have fiberglass underneath it.



I am working on getting the surface of the hood and the nose to be continuous, so more sanding with the flexible long board.

[freebeard]

You haven't specified your motor/generator choice yet, right?

If not, you might want to look at Hot-rodding the Toyota MGR in the Fossil Fuel Free subforum.



It's the one on the right.

[NeilBlanchard]

I am going electric, and this is the motor & gearbox I am hoping to use:



Neil Blanchard Designs: Rumination on Electric Drivetrain for CarBEN EV5

This is an AC induction motor with typical 95% efficiency. No permanent magnets, so virtually no drag during coasting. It is water cooled, as far as I know.

The 6.4:1 reduction differential is with no changes in the axis of rotation, and the left side output shaft passes through the inside of the motor; which has a tube for it's shaft. In total it weight a bit less than 79kg (174 pounds).

[NeilBlanchard]

I had a visit today from a gentleman from Spain, who has been following my CarBEN project, and he is in the area for a couple of months. He wanted to come and see it in person, so we dragged it out of the garage:



I also got to see his project, which is a solar / pedal electric 2 seat vehicle. He has a lot of experience building batteries. And also a way to do an open source project that can be truly collaborative. Lots of things to talk about, so we get together again before he leaves the area.



I did continue to refine the brow of the roof - it is much better now, but still needs some more work.

[freebeard]

He has a lot of experience building batteries. And also a way to do an open source project that can be truly collaborative.

Isn't all open source truly collaborative? What's his secret sauce?

It's nice to see it out in the light of day.

I hadn't seen your response on 20140915. You're budgeting $16K for batteries? The link for the transaxle 404s. But from their main page you can get to EV Transaxle assembly | Metric Mind Corporation. The transaxle uses ATF and the motor uses water for cooling?

You didn't give the specs on the motor, but the RPMs and gear reduction as similar to the Toyota/Lexus MGR. Those are $2300 new on eBay. What we have learned in the thread is that there exists a trailer towing option that adds an external oil cooler. Also cyruscosmo has a ton (literally, 2Klb) of aluminum to cast into custom gearset casings that he wants to make, using 3D printed wax for casting.

[NeilBlanchard]

What I mean is, it is a online CAD program that allows splitting and recombination and edit tracking, so that a complex project can be used by multiple people.

Thanks for the new link. I am not sure what I will have to pay for batteries or the drivetrain. The motor comes with a controller, and is AC synchronous, which is better for coasting.

I need to work on the more immediate hurdles, like getting my garage expanded so I can continue to work on the fiberglass. I need to go get my Saab 900 donor car soon, so I can then get the suspension parts in hand to see if they will work. I may have a big challenge with the width of the suspension and the half shafts with the motor.

[deejaaa]

great to hear about connections in far away places.
we are in Big Bend national park and met a couple from Holland so now WE have a connection in a far away place